Powered surgical handpiece with an antenna for reading data from a memory integral with a cutting accessory attached to the handpiece

ABSTRACT

A powered surgical handpiece that includes a motor for actuating a cutting accessory. The handpiece has a housing with a bore for receiving the cutting accessory and a coupling member internal to the bore that releasably engages and actuates the cutting accessory. A coil is mounted to the housing adjacent the bore. More particularly, the coil is located so that when the cutting accessory is seated in the bore, the coil is able to exchange signals with a complementary coil integral with the cutting accessory. A locking assembly mounted to the housing releasably holds the cutting accessory in the bore.

RELATIONSHIP TO EARLIER FILED APPLICATION

This Application is a divisional of application Ser. No. 10/214,937,filed 8 Aug. 2002, now abandoned which claims priority from theApplicant's U.S. Patent Application Ser. No. 60/310,957, SURGICAL TOOLSYSTEM WITH A CUTTING ACCESSORY THAT CONTAINS A MEMORY WITH DATA THATDESCRIBES THE OPERATING CHARACTERISTICS OF THE CUTTING ACCESSORY, filed8 Aug. 2001. The contents of the priority applications are incorporatedherein by reference.

BACKGROUND OF THE INVENTION

The Applicant's Assignee's U.S. Pat. No. 6,017,354, entitled INTEGRATEDSYSTEM FOR POWERED SURGICAL TOOLS, issued Jan. 25, 2000, andincorporated herein by reference, describes a surgical tool system witha handpiece that is removably attached to a control console. Internal tothe handpiece is a memory, a NOVRAM. The NOVRAM contains data thatdescribes the operating characteristics of the handpiece. For example,if the handpiece includes a motor, its NOVRAM includes data indicatingthe maximum speed at which the motor should run and, for given speeds,the maximum torque the motor is allowed to develop. Each time a newhandpiece is attached to the control console, the data in the handpieceNOVRAM is read by a complementary processor in the control console. Thecontrol console, based on the handpiece NOVRAM data, then supplies theappropriate energizaton signal to the handpiece motor.

An advantage of the foregoing system is that it allows a single controlconsole to be used to supply the energizaton signals that are applied tothe handpiece that have different power consuming units, such as motors.Thus, a single control console can be used to operate a first handpiecewith a motor that rotates at speeds under 3,000 RPM and requires 350Watts or more of power, a second handpiece that has a motor thatoperates at speeds over 70,000 RPM and that requires approximately 150Watts of power and a third handpiece that operates at speeds between10,000 to 40,000 RPM and that requires only 40 Watts of power.

In most surgical systems, the handpiece is not the actual component thatis applied to the surgical site in order to accomplish a surgical task.These components are, what are referred to as cutting accessories.

Typically, a single handpiece is used to actuate a number of differenttypes of cutting accessories. For example, a handpiece designed toperform some forms of ear, nose and throat surgery is designed toactuate both burrs and cutters. Burrs are cutting accessories designedto selectively shape and remove hard tissue, bone. Cutters are cuttingaccessories that are employed to selectively shape and remove softtissue such as sinus membrane tissue.

While a single handpiece is designed to actuate different types ofcutting accessories, the accessories themselves often have differentoperating characteristics. For example, some burrs may have a preferredoperating speed of 6,000 RPM and may be designed to operate at speeds ofup to 10,000 RPM. In contrast, some cutters may have a preferredoperating speed of 2,000 RPM and may be designed to operate at a maximumspeed of 5,000 RPM. Moreover, some cutting accessories are operated in adifferent manner than other cutting accessories. For example, a burr isdriven, rotated, in a single direction. A cutter is typicallyoscillated. In other words, when a cutter is actuated, it is typicallyrotated through an arc of X degrees in a first direction and thenrotated in the opposite direction through the same arc. Once this firstrotation cycle is complete, the motor driving the cutter repeats thisrotational pattern.

Often, during the course of a single surgical procedure, the surgeonwill want to apply two or more different cutting accessories to thesurgical site in order to accomplish the procedure. Typically, thesurgeon will use a single handpiece to actuate these different cuttingaccessories. Each time the surgeon attaches a different type of cuttingaccessory to the handpiece, it may be necessary for the surgeon or otheroperating room personnel to reconfigure the surgical system used todrive the cutting accessory to set it for the specific characteristicsof that accessory. When surgical personnel have to do this during thecourse of a surgical procedure, it can increase the overall time ittakes for the procedure to be performed. This is contrary to one of thegoals of modern surgery which is that it is desirable to perform asurgical procedure as quickly as possible in order to hold the overalltime a patient is kept under anesthesia to a minimum.

Moreover, having to have an individual in the operating room set thesurgical system to the operating characteristics of the cuttingaccessory that the system is being used to operate introduces thepossibility that, due to human error, these characteristics will beimproperly entered.

There have been some efforts at providing cutting accessories withtype-identifying indicators, typically magnets. The handpieces to whichthese accessories are attached are provided with sensors. These sensorsdetect the presence/absence of the magnets and generate signalsrepresentative of what was sensed back to the control console. Theprocessor in the control console, based on the signals from thehandpiece sensors, then configures the system.

The above system, while of some utility, only provides a limited amountof data about the cutting accessory attached to the system handpiece.This is because, due to space considerations, only a limited number ofindicators can be mounted to a cutting accessory and only a limitednumber of sensors can be fitted in the head end of the handpiecedesigned to actuate the accessory. For example, known commercial systemsof this design have handpieces with two sensors. Each sensor is designedto detect the presence/absence of a separate cutting accessory-mountedmagnet. Thus, these systems simply provide 2 bits of data. Even if itwere possible for the number of magnets in the cutting accessories andthe number of complementary handpiece sensors to be doubled, theresultant system would only be able to provide 4 bits of accessoryspecific data.

Thus, in the current systems, the indicators mounted to a cuttingaccessory are only employed to provide data that describes a basicoperating characteristic of the accessory or that describes its type.For example, the indicator may be employed to describe basic speed andtorque ranges of the cutting accessory or, for example, that theaccessory is a burr. Regardless of the specific nature of this data, thecontrol console processor, uses the data to reference complementarycontrol data in a look-up table or other circuitry internal to thecontrol console. The actual regulation of the handpiece is controlled byreference to this previously stored characteristic-data.

Thus, in the foregoing cutting accessory recognition system, the actualcontrol of the handpiece is based on operating parameters that have beenpreviously loaded into the control console. If a new accessory isprovided that has operating characteristics different than those thathave been loaded into the control console, the console will notautomatically configure itself to operate the handpiece in accordancewith those parameters. In order for this control to be accomplished, thecontrol console has to be loaded with the new operating characteristicdata. Moreover, given the limited amount of data that can be read fromthe indicators of the current systems, these data may be insufficient toprovide all the information a control console could use to regulate itsoperation based on the characteristics of the attached cuttingaccessory.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the basic system of this invention;

FIG. 2 is a cross-sectional diagram of a cutting accessory seated in thedistal end of a handpiece of this invention;

FIG. 3 is a block diagram of the circuitry internal to the controlconsole, the handpiece, and the cutting accessory that is used to storeand read data from the accessory that describes the characteristics ofthe cutting accessory;

FIG. 4 depicts the contents of the memory internal to the cuttingaccessory;

FIG. 5 is a block diagram of how the control console periodically readsthe contents of the memory of the cutting accessory and reconfigures theoperation of the system based on the retrieved data;

FIG. 6 depicts how the control console periodically determines whetheror not a particular cutting accessory attached to the handpiece has beenused for a time period equal to the useful lifetime of the handpiece;

FIG. 7 is a cross-sectional view of an alternative handpiece and cuttingaccessory of this invention;

FIG. 8 is a cross-sectional view of locking collet of the handpiece ofFIG. 7;

FIG. 9 is a plan view of the hub of the cutting accessory of FIG. 7;

FIG. 10 is a cross-sectional view of the coil seal of the cuttingaccessory of FIG. 7;

FIG. 11 is a perspective view of the coil seal of the cutting accessoryof FIG. 7;

FIG. 11A is a perspective view of the cutting accessory tag assembly;

FIG. 12 is a perspective view of a partially assembled alternativehandpiece of this invention in which a cutting accessory hub is showncoupled to the handpiece;

FIG. 13 is a front view of the handpiece and cutting accessory hub ofFIG. 12;

FIG. 14 is a cross sectional view of the handpiece and cutting accessoryhub taken along line 14-14 of FIG. 13;

FIGS. 15A and 15B are, respectively, perspective and cross sectionalviews of the handpiece coil housing;

FIG. 16 is a plan view of one coil assembly of this invention;

FIG. 17 is a plan view of the outer hub of FIG. 12;

FIG. 18 is a cross sectional view of the outer hub taken along line18-18 of FIG. 17;

FIG. 19 is a perspective view of a chip-and-coil subassembly, a tag, ofthis invention;

FIG. 20 is a block diagram view of an alternative version of thisinvention;

FIG. 21 is a block diagram depiction of how this invention may beintegrated in a surgical navigation system;

FIG. 22 is a cross sectional view of a cutting accessory of the versionof this invention depicted in FIG. 21;

FIG. 23 is a flow chart depicting how the control console determines theextent to which a particular cutting accessory is worn;

FIG. 24 is a block diagram of the inside of the control consoledepicting how separate controllers regulate the actuating of handpiecesand the reading of data from the NOVRAMs integral with the cuttingaccessories attached to the handpieces;

FIG. 25 is flow chart depicting an alternative process by which data ina cutting accessory NOVRAM are read;

FIG. 26 is a flow chart depicting an alternative process by which datain a cutting accessory NOVRAM are read and the control consoleconfigured to energize the handpiece to which the cutting accessory isattached;

FIG. 27 is a flow chart depicting how the integrated cutting accessoryand implant recognition system of this invention can be used tofacilitate the performance of image guided surgery;

FIG. 28 is a diagrammatic illustration of a case, such as asterilization case or a trial case, in which components used tofacilitate the performance of a surgical procedure are held;

FIG. 29 is a flow chart depicting how the integrated cutting accessoryand implant recognition system of this invention can be used tofacilitate the inventory of components used during the performance of asurgical procedure; and

FIG. 30 is a block diagram of how the information generated by theintegrated cutting accessory and implant recognition system of thisinvention are transferred to other components of a medical facility datainformation network.

FIG. 31 is a block diagram of the circuitry internal to a cordlesspowered surgical tool and a cutting accessory that is used therewith.

DETAILED DESCRIPTION

FIG. 1 depicts the surgical system 20 of this invention. System 20includes a surgical handpiece 22 that is used to actuate a cuttingaccessory 24 that is removably attached to the handpiece. Internal tothe handpiece is a motor 26 (FIG. 2) that is actuated to drive thecutting accessory 24. The handpiece 22 is removably attached to acontrol console 28 by a flexible cable 30. The control console 28contains circuitry that is used to supply energization signals to thehandpiece motor 26. The regulation of these energization signals iscontrolled by a microprocessor, controller 70 (FIG. 3), internal to thecontrol console 28. Internal to the handpiece 22 or the cable 30 is aNOVRAM 32. (When the NOVRAM 32 is in the cable 30, the cable isintegrally attached to the handpiece 22.) The NOVRAM 32 contains datathat describes the operating characteristics of the handpiece 22. Thesedata include: information that identifies the type of handpiece;information that describes the operating characteristics of thehandpiece motor; the identification of the type of output signalsprovided by any sensors internal to the handpiece; and informationuseful for correcting the signals produced by the handpiece sensors tocorrect for their individual calibration characteristics. Moreinformation on the types of data contained in the handpiece NOVRAM 32and how this information is used to regulate the operation of thehandpiece 22 by the system 20 is found in U.S. Pat. No. 6,017,354, whichis, again, incorporated herein by reference.

FIG. 1 further includes disposable tubing set 31. The tubing set 31includes tubing 33 and a cartridge 35. A portion of the tubing 33extends through and is secured to the cartridge 35. The cartridgeincludes an identification chip 37.

A first end of the tubing 33 is secured to and receives irrigationfluid, such as saline from an IV bag 39. The cartridge 35 is mountedonto the control console 28. A positive displacement pump (not shown) ofthe control console pumps the solution to a second distal end of thetubing 33 to irrigate a surgical site. The tubing 33 is adjacent anirrigation/cutting handpiece 41. A flexible cable 30 a connects thehandpiece 41 to the control console 28. The tubing 33 is positionedadjacent to the entire length of the cable 30 a. A cutting saw 43 islocated at a distal end of the handpiece 41. Other cutting elements canbe utilized in place of the saw 43.

The cartridge 35 can be any structure designed for securement to thecontrol console. In some embodiments, the tubing set 31 comprises onlytubing 31 and an identification chip 37. In this instance, the tubing 33is secured to the control console 28 so that the pump can pumpirrigation fluid to the distal end of the tubing.

In operation, the user of the irrigation/cutting handpiece 41 actuatesthe cutting saw 43. Power is supplied to the cutting saw via cable 30 a.When the cutting saw 43 is actuated, tubing 33 provides irrigation fluidto the surgical site.

When the cartridge 35 is installed onto the console 28, a coil (notshown) mounted on the console adjacent the cartridge reads data from theidentification chip 37. The data provides the diameter, size and anyother relevant properties for the tubing 33. The control console 28 thencontrols the positive displacement pump to provide a proper flow ratefor the irrigation fluid being applied to the surgical site duringcutting. Thus, a user need not manually set specific control values forthe pump.

Since the tubing set 31 is disposable, typically only data is read fromthe identification chip 37. However, in some embodiments data is sent tothe chip 37 indicating that the tubing set has been used and must bedisposed of.

In some embodiments, no cartridge 35 is present. The tubing 33 iswrapped or otherwise configured to the pump, which is preferably mountedonto the control console 28. In this instance the identification chip 37is mounted directly to the tubing 33, which comprises of itself, thetubing set 31. However, the identification chip 37 must be positionedadjacent a detector coil connected to the control console 28.

FIG. 2 illustrates the distal end of the handpiece 22 and the proximalend of the cutting accessory 24 of this invention. (In this application,“distal” is used to refer to a portion of a component located away froma surgeon/towards a surgical site; “proximal” refers to a portion of acomponent located towards the surgeon/away from the surgical site.)

The handpiece 22 has a housing 34. Motor 26 is disposed in the housing34. The motor 26 has a rotated-sleeve shaped shaft 36 to which a numberof magnets 38 are attached. Motor 26 also includes a set of windings 40that are secured to the inner wall of housing 34 that surround magnets38. The distal end of housing 34 is open and dimensioned to receive theproximal end of cutting accessory 24.

The cutting accessory 24 includes an outer hub 44 formed of plastic.Outer hub 44 is formed with tabs 46. Tabs 46 seat in complementarynotches 48 formed in handpiece housing 34 so as to hold the hub in oneplace in the housing. A locking mechanism integral with the handpiece,(not illustrated) has members designed to engage the outer hub 44 so asto releasably secure the cutting accessory to the handpiece. Forexample, some handpieces are provided with a set of ball bearings thatare releasably pressed against an opposed outer surface of the outerhub. The Applicant's Assignee's U.S. Pat. No. 6,312,441, POWEREDSURGICAL HANDPIECE FOR PERFORMING ENDOSCOPIC PROCEDURES, issued Nov. 6,2001 and incorporated herein by reference discloses how one such lockingassembly works. Alternatively, spring arms may be releaseably heldagainst the outer hub. The Applicant's Assignee's U.S. Pat. No.5,192,292, SURGICAL APPARATUS FOR ARTHROSCOPIC SURGERY, issued Mar. 9,1993 and incorporated herein by reference discloses one version of thistype of locking assembly. Thus, the actual type of handpiece lockingassembly that holds the cutting accessory to the 24 to the handpiece 22and complementary outer hub geometry may vary.

An outer tube 50 extends distally forward from the outer hub 44 awayfrom the handpiece 22. The cutting accessory 24 also includes an innertube 52 that is disposed inside the outer tube 50. The distal head endof the inner tube 52, (end not illustrated) is provided with some typeof cutting member to selectively shape and/or remove the tissue to whichit is applied. The inner tube 52 extends through both the outer tube 52and the outer hub 44. The proximal end of the inner tube is attached toan inner hub 56, sometimes referred to as a drive coupling, that islocated against the proximal facing face of the outer hub 44.

When the cutting accessory 24 is fitted in the handpiece, inner hub 56is located inside a cavity located in the distal end of the handpiecehousing 34. The proximal end of the inner tube 52 and inner hub 56 isseated over the open distal end of handpiece shaft 36. Complementaryteeth on the shaft 36 and the inner hub 56 releasably hold the inner hubto the shaft so that the inner hub will rotate in unison with the shaft36 (teeth not illustrated).

An identification sleeve 60 is fitted over the outer hub 44. Sleeve 60is formed of plastic and may provide some of the structural strength ofthe outer hub 44. Internal to sleeve 60 is a small semiconductor thatfunctions as an identification chip 62. Also disposed inside sleeve 60is a coil 64. In the depicted version of the invention, coil 64 extendsannularly around sleeve 60. The ends of coil 64 are, as described below,connected to components internal to identification chip 62.

The distal end, the head end, of handpiece housing 34 is provided with aseparate annular coil 66. The opposed ends of coil 66 are connected byconductors 63 (one shown) and cable 30 to circuitry internal to thecontrol console 28. Collectively, the handpiece 22 and cutting accessory24 are shaped so that coils 64 and 66 are in such proximity to eachother that they will collectively inductively transfer signals from/tothe circuit internal to the control console to/from the circuit internalto the identification chip 62. Typically, the handpiece housing 34 isformed of metal. Accordingly, in the illustrated versions of theinvention, coil 66 is disposed in a ring 67 formed from a plastic thatcan be subjected to medical sterilization wherein the handpiece isautoclaved at 270.degree. F., subjected to saturated water vapor at 30psi. One suitable plastic from which ring 67 may be formed is apolyetherimide and glass filed plastic sold by the General ElectricCompany under the trademark ULTEM. Ring 67 is fitted in a notch, notidentified, formed in an interior wall of handpiece housing 34. Theinner surface of ring 67 thus defines part of the cavity in which theproximal end of the cutting accessory 24 is seated. The fitting ofhandpiece coil 66 in ring 67 facilitates the inductive signal transferbetween the handpiece coil and the coil 64 integral with the cuttingaccessory.

FIG. 3 depicts, in block diagram, electrical components internal tocontrol console 28 of system 20 of this invention. The control console28 includes a controller (CNTRLR) 70 that controls the overall operationof the system 20. Memories, represented by a single memory 69, are alsocontained in the control console. These memories contain the permanentoperating instructions that are executed by controller 70 to control thesystem and regulate the actuation of the handpiece 22 and the cuttingaccessory 24. The memories also temporarily store the data that is readfrom the handpiece NOVRAM 32. As part of its control of system 20,controller 70 generates energization control signals to a driver 72. Thedriver 72, based in part on the energization control signals, generatesenergization signals that are applied to the handpiece motor 26.Controller 70 is connected to the handpiece NOVRAM 32 to receive fromthe NOVRAM the data that describes the operating characteristics of themotor. The control console 28 also includes a touch screen display 71.Controller 70 causes information regarding the state of the system 20 tobe presented on the display 71. Controller 70 also causes images ofbuttons to be presented on the display 71. Operating room personnelregulate the operation of the system 20 by selectively depressing thesebuttons.

Control console 28 is also connected to a modulator (MOD) 74. Modulator74 modulates digital signals output by controller 70 so they can beinductively transferred to cutting accessory identification chip 62. Inone preferred version of the invention, modulator 74 receives afixed-frequency signal from an oscillator 76 internal to the controlconsole 28. In one version of the invention, the signal produced by theoscillator 76 is at a frequency of 125 Khz. In another preferred versionof the invention, the carrier signal produced by oscillator 76 is at13.56 MHz.

Modulator 74, based on the bit stream produced by the controller 70,engages in selective amplitude shift keying (ASK) of the carrier signal.In one form of amplitude shift keying, based on the 1's and 0's patternthat forms the bit stream, the modulator 74 selectively transmits/stopstransmitting the carrier signal so as to produce a set of variablelength rectangular pulses. The amplitude shift keyed signal generated bymodulator 74 is amplified by an amplifier 78 internal to the controlconsole 28. The output signal from amplifier 78 is applied to one end ofhandpiece coil 66.

The end of handpiece coil 66 opposite the end to which amplifier 78 isconnected is tied to a demodulator (DEMOD) 80 internal to the controlconsole. Demodulator 80 receives the signal that is coupled to handpiececoil 66, demodulates the signal, and applies the output bit stream tocontroller 70. A typical demodulator may include a product detector towhich the carrier signal is applied from oscillator 76. The output fromthe detector, which is a multiplication of the signal from theoscillator 76 and the coil 66, is applied to a low-pass filter, alsopart of the demodulator 80. The output signal from the low pass filteris a bit stream that is applied to the controller 70.

In FIG. 3 oscillator 76 is also shown as connected to controller 70.This is because the signal produced by the oscillator is also used toregulate the writing out of the bit stream that is applied to themodulator 74 and the reading in of the bit stream generated by thedemodulator 80.

The identification chip 62 includes a small controller and anelectronically programmable memory (μC & MEM) 84. Controller/memory 84is capable of storing approximately 1 k bits of data. The controllerintegral with controller/memory 84 is capable of controlling the writingof data into its complementary memory section and the writing out of thecontents of the memory. There is also a modulator/demodulator (MOD DEM)86 fabricated integrally into chip 62. Modulator/demodulator 86 containsthe components necessary to demodulate the ASK signal coupled to coil 64and apply the resultant bit stream to controller/memory 84.Modulator/demodulator 86 also accepts the bit stream output from thecontroller/memory 84 and produces an ASK modulated signal based on thisbit stream. A clock 88 fabricated into chip 62 produces a clock signalthat the modulator/demodulator 86 uses as a basis for producing acarrier signal produced an ASK modulated signal.

A capacitor 83 is also fabricated integrally with chip 62. Moreparticularly, chip 62 is designed so that coil 64 is connected acrossthe opposed ends of capacitor 83. When a signal is applied to chip 62through coil 64, the energy in the high portion of the signal is storedin capacitor 83. This energy is applied directly to a power regulator 89to function as an energization signal. The power regulator 89 suppliesthis energization signal to the other sub-circuits internal to the chip62. (Connections between power regulator 89 and other components of chip62 not shown.)

In FIG. 3, coil 64 is shown as being integrally part of chip 62. This isone option for the invention. However, as discussed above, it isanticipated that in many versions of the invention, chip 62 and coil 64will be separate components.

FIG. 4 illustrates some of the different types of data stored in the tagcontroller/memory 84. These data include a serial number specific to thecutting accessory 24 with which tag 62 is integral, field 90. Thisnumber may also include a special authorization code, the purpose ofwhich is described hereinafter. There is also a field with data thatindicates cutting accessory's 24 type, field 92. For example, the datain field 92 may indicate that the cutting accessory is a burr that has ahead with a particular diameter. Field 94 within controller/memory 84contains data indicating a preferred speed at which the cuttingaccessory should be operated. Data indicating the maximum speed at whichthe cutting accessory should operate is contained in field 96. Themaximum operating torque the cutting accessory should develop isindicated by data in field 98.

Field 102 contains data that indicates the preferred mode of operationof the cutting accessory. For example, if the cutting accessory 24 is acutter, the most common mode of its operation is oscillatory.Alternatively, if the cutting accessory 24 is a burr, the preferred modeof operation is unidirectional. Stopping torque data is contained withina field 104. The stopping torque data is data used to regulate thedeceleration of the handpiece motor 26.

Controller/memory 84 also contains data fields that are written to bythe control console controller 70. One of these data fields is adate/time used field 106. Field 106 is used to store data indicating ifand when the cutting accessory 24 was previously used. Specifically,during loading of basic information into the controller/memory 84, field106 is loaded with flag data indicating that it has not been previouslyused. As described below, once the cutting accessory 24 is used, thecontroller 70 writes into field 106 an indication of when the useoccurs.

A set of data indicating for how long the cutting accessory can be usedis loaded into a MAX USE TIME data field 108 in controller/memory 84.This particular data represents how long a surgeon can expect to use thecutting accessory 24 before the cutting surfaces become worn to thelevel at which they may not efficiently cut tissue. The length of timecontained in field 108 may be based on empirical studies indicating howlong an accessory can be used before its cutting surfaces becomeexcessively worn. The MAX USE TIME field 108 is loaded with dataspecifying this time period when the other permanentaccessory-describing data are loaded into controller/memory 84. Thecontroller/memory 84 also includes a TIME USED field 110. Datarepresentative of the amount of time the cutting accessory has been usedis stored in TIME USED field 110 by control console controller 70. AWEAR PROFILE field 112 contains data indicating the extent to which thecutting accessory has been worn during its use.

The system 20 of this invention is initially configured for operation byconnecting the handpiece 22 to the control console 28. Controller 70reads the data in the handpiece NOVRAM 32, stores these data in memory69 and initially configures the system 20 to operate based on the datacontained in the NOVRAM. Handpiece NOVRAM 32 also contains a data field,(not illustrated), that indicates whether or not the cutting accessoriesattached to the handpiece 22 may contain an identification chip 62. Ifthis data indicates no such chip may be present, system 20 controls theactuation of the handpiece 22 based on the configuration data containedin NOVRAM 32.

If, however, NOVRAM 32 indicates that the cutting accessory may containa chip 62, controller 70 executes a read request, step 120 in FIG. 5, inwhich it reads the data in the chip controller/memory 84. In step 120,controller 70 generates a read request to chip 62. This request isconverted into an ASK signal by modulator 74 and applied to the chipthrough coils 64 and 66. If a chip 62 is attached to cutting accessory24, the chip, in response to the read request, writes out the storeddata in its controller/memory 84 through coils 64 and 69 and demodulator80 to controller 70. Controller 70 stores this data in appropriatefields within control console memory 69.

If the cutting accessory 24 does not include a chip 62, controller 70does not receive any data in response to its read request. If this eventoccurs, controller 70 regulates the operation of the handpiece based onthe data contained in NOVRAM 32, step not shown.

If cutting accessory chip 62 writes data to control console controller70, the first thing the controller does is compare the serial numberstored in chip 62 to the serial number stored from the last cuttingaccessory attached to the handpiece, step 122. If this is the firstcutting accessory attached to the handpiece 22, the serial number thecontroller 70 has stored will be a set of flag data indicating that,previously, there was no attached cutting accessory with chip.

Once it has been determined that a new cutting accessory has beenattached to the handpiece 22, step 122 may also include the sub-step of,determining based on the identification number, if the appropriateauthorization code is present. If this code is not present the controlconsole 70 may prevent further operation of the system with the attachedcutting accessory 24 and/or generate a message on display 71 indicatingthat an unauthorized accessory is attached. (The sub-steps of this codedetermination and the steps executed when the code is not present arenot illustrated.)

If the comparison of step 122 indicates that this is the first cuttingaccessory attached to the handpiece or, as discussed below, there hasbeen a change in the cutting accessory attached to the handpiece,controller 70 reads and reviews the data read from the tag data/timeused field 106. Specifically, in step 123, this data is reviewed todetermine whether or not the cutting accessory was previously used and,if so, did the use occur at a date and time significantly before thecurrent data and time. The data in chip 62 may indicate that there wasno previous use of the cutting accessory. Alternatively, if the dataindicates that the use of the cutting accessory was relatively recent,within, for example, 24 hours, controller 70 interprets this data asindicating that the use was in association with the current surgicalprocedure. Controller 70 interprets either of these two states as beingones in which use of the cutting accessory can continue normally.

However, in step 123, controller 70, based on the data read from field108, may determine that the cutting accessory 26 was previously used ata time other than during the current surgical procedure. If thisdetermination is made, controller 70 generates a warning messageindicating this information on the console touch screen display 71, step124. This provides the surgeon with an indication that the cuttingaccessory was used. In step 124, the controller presents a button ondisplay 71 the surgeon must depress to acknowledge the used state of thecutting accessory before it allows the surgeon to actuate the handpiece22.

Once it is determined that the cutting accessory 24 was not previouslyused, or the surgeon has acknowledged the previous use, controller 70reconfigures the operation of the system, step 126. In step 126, basedon the data read from the controller/memory 84 integral with the cuttingaccessory 24, controller 70 configures the system for operation with thecutting accessory. Specifically, the system 20 is set so that at leastinitially the handpiece motor will operate at the speed indicated by thedata in preferred speed field 94. The forward/reverse/oscillate mode ofthe motor is set to that specified in operating mode field 102. Thus, instep 126, the data from the cutting accessory chip 62 is used tooverride data that supersedes the data in handpiece NOVRAM 32 thatdescribes how the system should be configured. Not illustrated is thememory integral with controller 70 in which the data from chip 62 arestored and used as reference data to control the operation of the system20.

In step 126, based on the data contained in the accessory type field 92,controller 70 causes console display 71 to present an indication of theaccessory's type. Controller 70 further configures the system to preventthe surgeon for generating commands that allow the handpiece motor to beactuated at a speed greater than that specified in the maximum speedfield 96. (Alternatively, controller 70 may simply require the surgeonto acknowledge a warning before allowing the surgeon to operate thehandpiece above the maximum speed for the associated accessory 24.)System 20 is further configured by controller 70 to prevent thegeneration of energization signals from being applied to the handpiecemotor that would cause the cutting accessory 24 to develop more torquethan it is allowed to develop according to the data in maximum torquefield 98. The system is further configured so that during decelerationof the handpiece motor, the motor will not be subjected to torque inexcess of the braking torque specified in stopping torque field 106.

Controller 70 also updates the data in the controller/memory 84 of thecutting accessory 24, step 128. More particularly, in step 126, the dateand time the cutting accessory 24 was attached to the handpiece 22 arewritten into the date/time used field 106.

Once steps 126 and 128 are executed, the system is ready for operation.The control console will, based on commands entered by the surgeon,apply energization signals to the handpiece motor 26 so that it will runin the appropriate mode and in appropriate speed for that attachedcutting accessory 24. This operation of the system is represented bycontinued operation step 130 of FIG. 4.

Throughout the operation of the system 20, controller 70 willperiodically execute read request/data read and serial number comparisonsteps 120 and 122, respectively. In some versions of the system, steps120 and 122 are reexecuted once every 0.2 to 1.0 seconds during periodsof time the handpiece is not being actuated. If the serial numbercomparison step 122 indicates that serial number associated with thecutting accessory 24 is unchanged, controller 70 recognizes this stateas indicating that the same cutting accessory remains attached to thehandpiece 22. If this condition is detected, controller continues toallow the system to operate in accordance with its currentconfiguration; step 130 is continually executed.

However, serial number comparison step 122 may indicate that there hasbeen a change in cutting accessory serial numbers since the step waspreviously executed. This condition is recognized by controller 70 asindicating that a different cutting accessory 24 is attached to thehandpiece 22. If this is the detected system state, controller 70reexecutes steps 123, 126 and 128, and, if necessary, step, 124, beforereexecuting step continued operation step 128. When continuing operationstep 128 is reexecuted, the system 20 has been reconfigured to actuatethe handpiece in accordance with the characteristics of the newlyattached cutting accessory 24.

Controller 70 also monitors the amount of time the cutting accessory 24is actuated. Specifically, controller 70 maintains an internal timer inwhich a time count is maintained indicating how long the cuttingaccessory attached to the handpiece 22 is actuated. In some versions ofthe invention, after each time the motor is deactivated, step 138 ofFIG. 6, the controller 70 performs this monitoring. Specifically, afterthe motor is deactivated, controller 70 performs a step 140 in which thecontroller writes into the TIME USED field 110 of the cutting accessorycontroller/memory 84 data indicating the total time the cuttingaccessory has been used. These data are determined based on the dataread from the TIME USED field 110 when the cutting accessory was firstattached to the handpiece as well as the elapsed time of use for theaccessory stored by the controller 70. This step 140 may be integratedinto the first reexecution of step 120 after the motor is deactivated.Alternatively, step 140 may be executed as a separate write data stepafter the motor is deactivated. As part of step 140, the elapsed timecount held by the internal timer is zeroed out.

Controller 70 then determines if the total time the cutting accessoryhas been used is less than the time period specified in the MAX USE TIMEfield 108 of the cutting accessory 24, step 142. In some versions of theinvention, it is believed the useful lifetime for a cutting accessorywill be between, for example, 30 and 120 minutes. If the total use timeis less than the maximum recommended use time, controller 70 allows thesystem to operate as before, step 144. If, however, the total time ofuse is greater than the specified maximum recommended use time,controller 70 presents a warning notice and an acknowledgement button onthe touch screen display, step 146. The surgeon must acknowledge thatthe cutting accessory 24 has been used for a time greater than itsspecified maximum use before the controller allows the system tocontinue to actuate the cutting accessory 24.

Chip 64 of cutting accessory 24 of this invention contains a significantamount of data that describes the operating characteristics and state ofthe cutting accessory. The control console 28 of this systemautomatically both reads this data and periodically updates it. Thecontrol console 28, based on the data read from chip 64, configures thesystem so it will operate in an appropriate manner given the specificcharacteristics of the specific attached cutting accessory.Specifically, the control console controller 70 configures the system sothat, at least initially the handpiece motor will run at the preferredspeed and in the preferred mode for the cutting accessory. The system isalso configured to prevent the cutting accessory from being driven aboveits specific maximum operating speed, from developing torque beyond itsdesign limit and from being subjected to excessive braking torque. Thisconfiguration of the system occurs without human intervention.Consequently, the possibility that human error could result in theincorrect configuration of the system 20 for the cutting accessory 24attached to it is substantially eliminated.

The system of this invention provides the surgeon with an indication ofwhether or not the cutting accessory attached to it was previously used.This provides the surgeon with an indication that the cutting accessorymay be worn and, therefore, will not be able to satisfactorily performthe intended surgical procedure.

System 20 of this invention also, during the surgical procedure,provides the surgeon an indication that a cutting accessory has beenused for a period equal to its intended lifetime. This information issupplied to the surgeon to inform him/her that the cutting accessory,even if new when installed, may be worn to the level of reducedefficiency. Thus, the surgeon, upon receiving this information, candecide whether or not to continue using the current accessory or replaceit with a new one.

Moreover, the handpiece 22 of this invention is constructed so that ring67, which functions as the inner wall in which coil 66 is contained isplastic and the handpiece housing 34, which forms the outer containmentwall for the coil, is formed of metal. As a result of this construction,the inductive field generated by coil 66 is localized within the cavityin the distal end of the housing 34 in which cutting accessory 24 isseated. The inductive field generated by coil 66 does not extend beyondthe surface of housing 34. This substantially eliminates the possibilitythat if the handpiece of this invention was placed on a surface next toa cutting accessory that is provided with an identification chip 64, thehandpiece coil 66 will not establish an inductively coupled circuit soas to provide the control console 28 with a false indication that thehandpiece is actually connected to the adjacent cutting accessory.

It should be recognized that the foregoing description has been limitedto one preferred version of the invention. Other versions of theinvention may vary from what has been described. For example, in someversions of the invention, the coils integral with the cutting accessoryand handpiece may not extend circumferentially around the longitudinalaxis of these components. Instead, these coils may be positioned to bealigned longitudinally with the longitudinal axes of the cuttingaccessory and handpiece.

Also, in some versions of the invention, the handpiece may beconstructed so that the material in which coil 66 is encased is metal.Thus, in these versions of the invention, the presence of coil 66 doesnot require the handpiece to have a non-metallic component that isdirectly exposed to the rigors of sterilization.

Moreover, the data contained within the chip 62 of the handpiece mayvary from what has been described. For instance, in some versions of theinvention, the handpiece of the invention may not include a NOVRAM. Inthese versions of the invention, chip 62 contains all, or substantiallyall, of the handpiece characteristic data that was otherwise stored inthe handpiece NOVRAM. This data is, however, specific to the operatingcharacteristics of the cutting accessory 24 with which the chip 62 isintegral. Once the cutting accessory 24 is attached to the handpiece 22,controller 70 configures the system based on the data read from the chip62.

Also, in some versions of the invention, it may not be possible for thecutting accessory to overwrite new data into any data field. In theseversions of the invention, the chip 62 has empty data fields when it isinstalled in the cutting accessory 24. Then, during operation of thesystem 20, controller 70 writes the new data that needs to be writteninto chip 62 into the previously empty controller/memory data fields.During the read out of the contents of the controller/memory 84, step120, all the data are read out. The controller is configured torecognize the last data in a set of data fields, for example in a set oftime used fields, as being the most current version of the data.

FIG. 7 depicts an alternative handpiece 150 and cutting accessory 152constructed in accordance with this invention. Specifically, thehandpiece 150 has a metal body 154 to which a plastic locking collet 156is attached. Internal to the body is a motor, not illustrated, fromwhich a drive shaft 158 extends. The cutting accessory 152 has a statichub 160 that is releasably held to the handpiece 150 by a lockingassembly mounted in the locking collet 156. The locking assembly, whilenot fully illustrated, includes a tongue 157 that is releasably seatedin a recessed surface of hub 160. A tubular housing or outer tube 162extends from hub 160. Located proximal to hub 160 and within thehandpiece 150 is a drive coupler 164. Drive coupler 164 has a proximalend designed to engage a coupling member integral with drive shaft 158so that the shaft and coupler rotate in unison. A drive shaft, or innertube 166 is secured and extends distally from the drive coupler 164. Thedrive shaft 166 extends through hub 160 and into housing 162.

An RFID chip 170 (FIG. 11A) is secured to hub 160. A coil 172 isconnected to chip 170. A coil 174 is mounted to handpiece body 154.Handpiece coil 174 inductively exchanges signals with chip 170 throughcoil 172.

Handpiece body 154 is generally elongated in shape and has elongatedbore 177. Bore 177 is the space in which the handpiece motor as well asthe proximal end of the cutting accessory 152 are seated. The distal endof body 154 is shaped to have a ring shaped head 178 that defines acounterbore 180 that opens into bore 177. Counterbore 180 opens into amain bore in the body in which the motor is housed. A suction bore 182branches off of bore 177. Suction is drawn through the cutting accessory152 through the suction bore 182. Partially seen in FIG. 7 is a valvebore 184 that interests the suction bore. A valve (not illustrated,) isdisposed in the valve bore 184, for regulating the suction flow throughthe cutting accessory 152 and the handpiece 150.

Handpiece body 154 is further formed so that the distal end portion ofthe inner wall of head 178 has an inwardly directed step 186. Coil 174is disposed in the space defined by step 186. In some versions of theinvention, coil 174 is in the helical wrap of wire. The wire may bewrapped around a thin film of polyamide material that supports the wire.In alternative versions of the invention, coil 174 is formed on flexcircuit. The flex circuit is placed in the space adjacent step 186.

Conductors 188 that connect coil 174 to downline components in thehandpiece 150 are seated in a separate bore 189 formed in the housingbody 154. Specifically, internal to the handpiece is an impedancematching circuit that establishes the impedance of the circuit internalto the handpiece to 50 Ohms to facilitate the exchange of the signalsbetween control console 28 and coil 174 over a 50 Ohm impedance coaxialcable.

Locking collet 156, seen best by reference to FIG. 8, has a tubular base190. Extending distally from base 190, collet 156 is shaped to have ahead 192 that has a larger outer diameter to base 190. The movingcomponents of the locking assembly that engage hub 160 are mounted inbase 190.

When the handpiece 150 is assembled, collet base 190 is fitted incounterbore 180 so that the outer wall of the base abuts the inner wallof body proximal to step 186. An O-ring 194 is located around theinterface where the proximal end of collet base 190 abuts the handpiecebody 154. Specifically, the collet base 190 is formed to define a groove196 that extends circumferentially around the distal end of the outerperimeter of the proximal end of the base 190. In order to providestructural strength for the collet, it will be observed that theproximal end is located inwardly of the more distal sections of thebase. The handpiece body is shaped to define an annular stepped surface198. The stepped surface is the surface from which the body head 178extends. Stepped surface 198 is the surface against which the proximalfacing end of collet base 190 extends. Housing body 154 is furtherformed so that there is a small grooved surface 202 within steppedsurface 198. Specifically, grooved surface 202 extends annularly aroundstepped surface 198 adjacent the outer perimeter of the stepped surface.The O-ring 194 is thus seated in the grooved surface 202 of thehandpiece body 154 and groove 196 of collet 156.

Locking collet 156 is further formed to have a generally cylindricalouter ring 204 that extends proximally from head 192. Outer ring 204thus extends circumferentially around and is spaced away from the distalend of locking collet base 190.

When the handpiece 150 is assembled, coil 174 is seated in the annularspace between the outer wall of collet base 190 and the inner wall ofouter ring 204. In other words, this annular space forms an enclosurefor holding coil 174. The collet 156 is fitted to body 154 so that theouter surface of collet outer ring 204 is disposed against the innerwall of the base head 178.

As part of the process of assembling the handpiece 150, an adhesive,such as a silicone adhesive, is placed between the opposed surfaces ofthe body head 178 and collet outer ring 204. A fraction of this adhesivecollects in two annular channels 210 formed in the handpiece body head178. Upon the curing of this adhesive in the channels, the adhesiveforms two O-rings 211 between the body 154 and collet 156. These O-rings211 thus prevent fluid flow from outside the handpiece 150 to coil 174.

Hub 160, which is formed of rigid plastic, is now described by referenceto FIG. 9. The hub 160 is constructed to have a sleeve-shaped base 220.The base 220, it will be observed, is formed with two diametricallyopposed, generally rectangularly shaped openings 221. Extending forwardfrom base 220 and formed integrally therewith is a substantially solidhead 222. While head 222 is substantially solid, the hub 160 is formedso that a bore 224 extends axially through the head. Housing 162 ismounted in bore 224 in any conventional manner to extend forward fromhead 222.

A generally tube-shaped coil seal 226 is disposed in hub base 220. Coilseal 226 is formed from flexible sterilizable material. In one versionof the invention, coil seal 226 is formed from a silicon rubber that has55 Shore A durometer hardness. The coil seal 226 is shaped so as to havea first distal end section 228 that has a constant outer diameter andinner diameter. Extending proximally from the distal end section 228,the coil seal 226 has a main section 230. Main section 230 has the sameinner diameter as distal end section 228 and a smaller outer diameter.The coil seal is further formed so as to define a generally rectangularrecess 232 in the outer surface of main section 230. Located proximal tomain section 230, the coil seal 226 has a locking section 234. The innerand outer diameters of locking section 234 are the same as those of thedistal end section 228.

The locking section 234 of the coil seal is further formed to have twodiametrically opposed lock tabs 236. Each lock tab 236 extends radiallyoutwardly from the outer surface of the locking section 234. The lockingsection also has two diametrically opposed stop tabs 238 that extendinwardly from the inner wall of the lock section. In the depictedversion of the invention, each stop tab 238 is radially aligned with aseparate one of the lock tabs 236.

Coil seal 226 is further formed to have a tail section 240 that extendsrearwardly from the locking section and that forms the proximal end ofthe seal. The tail section 240 is formed to define two annular spacedapart ribs 242 and 244 that extend circumferentially around coil seal226. Both ribs 242 and 244 extend beyond the outer diameter of the seallocking section 234. In the depicted version of the invention, thediameter of the circle subtended by the more proximal of the two ribs,rib 244, is less than the diameter subtended by the other rib, rib 242.Tail section 240 is further formed to have an inner wall that isoutwardly flared.

When a cutting accessory 152 of this version of the invention isassembled, the RFID chip 170 is seated in seal recess 232. Coil 172 iswound over the reduced diameter outer surface of seal main section 230.In some versions of the invention, seen in FIG. 11A, the chip 170 ismounted on a small flex circuit 171; the coil 172 is a conductive traceformed on the flex circuit 171. After manufacture of the flex circuit171, the flex circuit, with the chip 170 mounted thereon, is wrapped incylinder over seal main section 230.

The RFID chip-coil-and-seal assembly is fitted in hub base 220. Thusboth the RFID chip 170 and coil 172 are disposed between the inner wallof the hub base and the outer surface of coil seal 226. Owing to therelative dimensions of hub 160 and coil seal 226, the outer surfaces ofthe seal distal end and locking sections 228 and 234, respectively,press against the inner wall of the hub base 220. This contact forms aseal around chip 170 and coil 172. Thus, in most preferred versions ofthe invention, there is no need to employ an adhesive or other chemicalto provide a moisture barrier around the chip 170 and coil 172.

As part of the insertion of the coil seal 226 into the hub 160, locktabs 236 are seated in hub base openings 221. The seating of the locktabs 236 in openings 221 serves to hold the coil seal 226 to the hub160.

When the coil seal 226 is so attached to hub 160, tail section ribs 242and 244 are located proximal to the proximal end of the hub. When theassembled cutting accessory 152 is fitted in the handpiece 150, ribs 242and 244 abut the inwardly flared surface of the handpiece collet base190. The ribs thus function as a seal that prevents leakage from thesuction channel to the coil cavity or the outside environment.

It will further be observed that the distal end of driver coupler 164 isformed with a head 245 that has a relatively large outer diameter. Whencutting accessory 152 is assembled, the driver coupler and rotatingshaft subassembly is moved past coil seal 226 in hub bore 224. Owing tothe dimensioning of the components, the drive coupler head 245 abuts thecoil seal stop tabs 238. Owing to the compressibility of the materialfrom which the coil seal is formed, a small amount of force willcompress the stop tabs 238 to allow the complete insertion of the drivecoupler and rotating shaft. After assembly, if the cutting accessory 152is held vertically, the drive coupler head 245 abuts the stop tabs 238.Thus, the stop tabs prevent gravity, without any additional force, fromcausing the driver coupler and rotating shaft to drop out of hub 160.

FIGS. 12, 13 and 14 illustrate an alternative handpiece 250 and cuttingaccessory hub 252 of this invention. The handpiece 250, shown incross-section in FIG. 14, includes an elongated body 254 that has anaxially extending bore 256. The center and proximal end sections of bore256 serve as the space in which the motor and cable connector integralwith the handpiece 250 are housed, (motor and cable connector notshown). The distal end section of bore 256 is the space internal to thehandpiece in which the cutting accessory hub and drive coupler arereceived, (drive coupler not shown).

This particular handpiece has a motor with a cannulated rotor. Thus,suction is drawn axially from the distal end of the rotating shaft ofthe attached cutting accessory, through the drive coupler and the motorrotor by the suction pump attached to the handpiece. Irrigation fluid issupplied to an opening in the hub 252. The irrigation fluid can also bedirected through the rotating shaft. A valve in the proximal end of bodybore 256 selectively connects the rotating shaft to either the suctionpump or the source of irrigating fluid. This valve is set by a controltab, (not illustrated), that is positioned above a stepped surface 258formed in the outside of body 254. The control tab displaces a linkagerod (not illustrated), that is seated in a rod bore 259 formed in thebody 254. The Applicant's Assignee's U.S. patent application, SYSTEM ANDMETHOD FOR PERFORMING IRRIGATED NOSE AND THROAT SURGERY Ser. No.60/395,881, filed on Jul. 13, 2002, now U.S. Pat. No. 7,318,831 B2, andincorporated herein by reference, provides further details of the abovefeatures of this handpiece.

A coil 260 is disposed in the distal end of body bore 256, immediatelyinside the distal end opening of bore 260. Coil 260, shown in FIG. 14 asa wrap of wires, is contained in a coil housing 262, now described byreference to FIGS. 15A and 15B. The coil housing 262 is formed from aplastic cable to withstand sterilization such as PEEK plastic and isgenerally ring-shaped. Coil housing 262 is further formed to define arectangular groove 264 that extends circumferentially around the outsideof the housing. Groove 264 is the space in which coil 260 is seated. Theproximal facing end of the coil housing 262 is formed to have an annularlip 266 that extends substantially circumferentially around the housing.Lip 266 has an outer diameter substantially equal to the outer diameterof the more distal portions of the coil housing. The inner diameter oflip 266 is greater than that of the rest of the housing 262.

Coil housing 262 is further formed to have a slot 268 that is defined byopposed spaced apart ends of lip 266. The wires forming coil 260 extendproximally into the handpiece body through slot 268.

When handpiece 250 is assembled, coil 260 is seated in housing groove264. The coil-and-housing assembly is seated in the distal end of bodybore 256. In some versions of the invention, the coil housing 262 isadhesively secured to a lock nut 270 disposed in body bore 256.Alternatively, coil housing 262 may be provided with feet that pressfit, snap fit or key-in-key hole slot fit into the lock nut. In someversions of the invention, the coil housing 262 may even press fit intobody bore 256.

The conductors connected to coil 260 extend proximally, rearwardly, fromthe coil and are disposed in a bore, signal conduit 259, formed in thehandpiece body 254. Signal conduit 259, it is observed from FIG. 14,extends generally parallel to bore 256. The distal end of signal conduit259 extends diagonally into the section of bore 256 in which coilhousing lip 266 is seated.

In one version of the invention, the conductors that extend to coil 260,as well as the conductors that actually form the coil, are formed on aflex circuit 272 now described by reference to FIG. 16. Flex circuit 272is formed of polyamide or any other material that can serve as astructural substrate for conductors and electrical components. Flexcircuit 272 has a first section, section 273 that is vertical in theFigure. A second section, section 284, extends away from the distal endof first section 273 such that the longitudinal axes of flex circuitsections 273 and 284 are angularly offset from each other. In thedepicted version of the invention, the flex circuit sections 273 and 284are angularly offset by 90° so the flex circuit 272 is L-shaped.Conductive traces 274, 276 and 278 are formed on the flex circuit 272.Two traces, traces 274 and 276 are parallel and are located on the firstsection 273 of the flex circuit in FIG. 16. An integrated circuit 280 isshown attached to trace 276. Circuit 280 is an impedance matchingcircuit to bring the impedance of the circuit on the trace to 50 Ohms.While not illustrated, it should be recognized that trace 274 is alsoattached to the integrated circuit 280. Trace 274 also terminates ashort distance above integrated circuit 280.

Trace 278 extends from integrated circuit 280 and is the conductivetrace formed on the second section 284 of flex circuit 272 in FIG. 16.The flex circuit 272 is further formed to have a small branch section286 that extends diagonally downward from the end of the second section284 opposite the first section 273. The free end of trace 278 is formedover the branch section 286.

When a version of the invention incorporating flex circuit 272 isassembled, second section 284 of the flex circuit is wrapped in acircular pattern at least once in coil housing groove 264. Morespecifically, the flex circuit 272 is wound in a closed circular shapearound the coil housing 262 so that flex circuit branch section 286extends over first section 273. Then, the free end of trace 278 issoldered or otherwise conductively connected to the free end of trace274. Thus trace 278 forms the handpiece coil.

The cutting accessory hub 252, now described by reference to FIGS. 17and 18, is formed from two plastic pieces, base 290 and head 292. Base290 is formed to have a proximal section 296 that has a multisectionaxial bore 298. It should be understood that bore 298 is dimensioned toreceive the drive coupler and proximal end of the rotating shaft of thecutting accessory with which hub 252 is integral. Base 290 also has adistal section 302 integrally formed with and located forward ofproximal section 296. Base distal section 302 is formed to have acounterbore 304 that has a diameter that is larger than the diameter ofthe adjacent section of bore 298.

The hub head 292 is formed to have an axially extending through bore308. Bore 308 is dimensioned to receive the associated rotating shaft.The hub head is shaped to have a generally cylindrical, proximallylocated stem section 310. Collectively the components forming hub 252are shaped so that stem section 310 has an outer diameter that isappreciably less than the inner diameter of base distal end section 302.

When hub 252 is assembled, head stem section 310 is seated in basecounterbore 304. Owing to the relative dimensions of the base 290 andhead 292, when these components are so assembled an annular coil space312 is formed between stem section 310 and the adjacent end wall of basedistal end section 302. An RFID chip 314 and coil 316, now described byreference to FIG. 19 are seated in this space. Specifically, the chip314 and coil 316 are assembled as a single unit on a flexible substrate318. Often this assembly is referred to as a tag. A chip from thePhilips Semiconductor of Netherlands i.Code family of chips can beemployed as the chip 314. Conductive traces that form coil 316 areformed on substrate 318. As part of the hub assembly process, prior tothe insertion of head 292 over base 290, substrate 318 is wrapped into acylindrical shape and inserted in base counterbore 304. The head stemsection 310 is then seated in counterbore 304. It will be understoodthat the base 290 and head 292 are dimensioned so that the proximal endof the head stem section abuts the step within base 290 that defines thebase of counterbore 304.

Adhesives hold the base 290 and head 292 together. The adhesives alsocreate a seal around coil space 312. In some versions of the invention,base 290 and head 292 may be provided with tongue-and-slot members tofurther facilitate the mechanical connection of these components.

When hub 252 is seated in handpiece 250, coil 316 is aligned with thehandpiece coil 260. Consequently, signals are inductively transmittedbetween the coils. In preferred versions of the invention, the voltageacross the handpiece coil is approximately 5 to 25 volts, the currentthrough the handpiece coil is approximately 25 to 125 m Amps. Given thisstrength of signal, and the fact that handpiece body 254 is metal, inpreferred versions of the invention, the inductive field established bythe handpiece coil does not extend more than 2 cm beyond the coil. Inmore preferred versions of the invention, this inductive field extends amaximum of 1 cm beyond the coil. Thus, the inductive field is sufficientto engage in signal transfer with the coil 316 of the hub inserted inthe handpiece 250, but not the coil integral with a cutting accessorythat may be located next to the handpiece.

It should likewise be understood that the system of this invention mayhave power-consuming devices other than motors. For example, inalternative versions of the invention, the handpiece power-consumingdevice may be some sort of heat generating device, light generatingdevice or sound/mechanical-vibration generating device. The energygenerated by these power-consuming devices are applied to surgical sitesthrough removable accessories different from what has been described.The accessories of these versions of the system of this invention areprovided with tags that have memories in which data describing theindividual operating characteristics of the accessories are stored.Clearly, different data are contained in cutting accessories that areactuated by devices other than motors. Also, the chip may be installedin accessories that are not actuated. One such device is a pointer thatis attached to a tracker that is used to facilitate the performance ofsurgical navigation.

It should likewise be understood that this invention may do more thansimply provide data or write data to a cutting accessory attached to ahandpiece. For example, some surgical tool systems include intermediateattachments 320, one shown diagrammatically in FIG. 20. Theseattachments 320 serve as mechanical, optical or electrical linkagesbetween the power generating unit internal to the handpiece 22 a and acutting accessory 24 a. In these versions of the invention, an RFID chip322 is mounted in a non-metallic ring integral with the attachment (ringnot illustrated). Upon connection of the attachment 320 to thehandpiece, a coil 324 integral with the attachment is in close enoughproximity to the handpiece coil 66 a that there is an inductive signaltransfer between these components. Based on the data read from theattachment, the control console 28 applies energization signals to thehandpiece power generating unit so that it operates in a mannerappropriate to the associated attachment and cutting accessories. Forexample, if the handpiece power generating unit is a motor, based on thedata read from the attachment connected to the handpiece, the powergenerating unit can establish a maximum speed for the motor and/ordetermine the maximum torque the motor should be allowed to develop.

In the above versions of the invention, the attachment may, as depictedin FIG. 20, have its own coil 326 for inductive coupling to the RFIDchip 62 integral with the associated cutting accessory 24 a. In thisversion of the invention, the processor internal to the control consoleengages in the following data reading protocol. First, an interrogationsignal is sent asking for data from an attachment RFID chip 322.Integral with this signal is data indicating the type of RFID chip, anattachment chip, that is supposed to respond to the interrogation. Basedon these data, only the attachment chip 322 responds. After the data inthe attachment RFID chip 322 are read, the control console generates asecond interrogation signal. Embedded in this signal are data indicatingthat an accessory chip 62 is supposed to respond to the interrogation.Based on this interrogation signal, only the accessory RFID chip 62writes out data back to the processor. Thus, the energizaton of thehandpiece power generating unit is based on data in the attachmentand/or any overriding data in the cutting accessory.

Also, as depicted in FIG. 21, in some versions of the invention, an RFIDchip may be placed in an implantable device 330 that is fitted into apatient, represented by bone section 332. Such devices include screws,reamers that are used to bore holes for implants, or implantsthemselves. Specifically the head of the device 330 is provided with aplastic ring in which an RFID chip 336 and complementary coil 338 areseated. The data in chip 336 include such information as the preferredand suggested maximum speeds for driving the implant into the patient.These data also describe the physical characteristics of the implant.For example, if the implant is a screw, the data describes: theimplantable length of the screw; the diameter of the screw; and the sizeof the exposed head.

In this version of the invention, the accessory 340 used to set theimplant, as seen in FIG. 22, is provided with a coil 342. Here, theaccessory 340 is a screw driving shaft. The accessory has a shaft 344formed of metal. Immediately proximal to the distal end, shaft 344 isformed to have a circumferentially extending groove 346. Coil 342 isdisposed in a plastic or other non-metallic housing 347 seated in groove346. Conductors, represented by a single conductor 348, extend through aconduit 349 that extends longitudinally through shaft 344. Theconductors 348 are connected to a coil 64 b disposed in the distal endhub 44 b of the accessory 340. Distal end hub 44 b, in addition toincluding coil 64 b also includes an RFID chip 62 b that contains datadescribing the characteristics of the accessory 340.

When the system of FIG. 21 is used, control console 28 is inductivelycoupled to both accessory chip 62 b and implant chip 336. This couplingoccurs immediately after the surgeon has depressed a control memberassociated with the system to actuate the handpiece 22 b. This isbecause, at this time, the surgeon has typically already pressed thedistal end head of the cutting accessory 340 against the adjacent headof the implant 330. Thus, at this time the data from the implant chip336 can be read. The data in these chips are read by the control console28. Based on these data, the control console regulates the applicationof energization signals to the handpiece 22 b to ensure that theaccessory 340 is driven at an appropriate speed for the complementaryimplant 330.

As part of this process, the control console 28 first verifies that theaccessory 340 is an appropriate type of accessory for driving theimplant. This verification may be performed by, first, determining thetype of implant from the data read from the implant chip 336. Then,based on data contained in the memory internal to the control console28, the control console determines if the accessory 340 can drive theimplant. Alternatively, the data in the implant chip 336 contains a listof the types of accessories 340 that are appropriate for driving theimplant. If initially, the control console 28, based on thedetermination of the type of accessory and the type of implant,determines that the accessory is inappropriate, the control consoleeither provides a warning message that the surgeon must acknowledge thisfact or prevents actuation of the handpiece 22 b.

If the accessory 340 is an appropriate accessory for driving theimplant, control console 28 configures the system so that energizationsignals are applied to the handpiece 22 b that will cause the accessoryto be driven at the preferred speed. If the surgeon attempts to drivethe accessory above an appropriate maximum speed for the implant 330 orthe accessory 340, at a minimum, the control console presents a warningthe surgeon must acknowledge before the procedure is allowed to proceed.

Control console 28 also forwards the data regarding the characteristicsof the implant 330 and the driving accessory 340 to a surgicalnavigation unit 350. Prior to this part of the procedure, the surgicalnavigation unit was provided with data that describes the physicaldimensions of the portion of the patient on which the procedure is beingperformed. A tracker, not shown is attached to the handpiece 22 b. Thesurgical navigation unit 350 monitors the position of the tracker. Whenthe surgical procedure is being performed, the surgical navigation unithas the following data: position of the tracker; data regarding thephysical characteristics of the handpiece 22 a and accessory 340; and,from the implant chip 336, data regarding the physical characteristicsof the implant 330. Based on these data and the stored image of thepatient, the surgical navigation unit 350 is able to determine theposition of the implant 330 as it is driven into the body of the patient332. This information is presented on a monitor 352.

Also, the surgical navigation unit 350 determines, based on the storeddata regarding the implant 330 and patient 332, if it appears that thereis a possibility that the implant is being inappropriately positioned inthe patient. For example, if the implant is a screw that is supposed toonly be driven into bone to a certain depth, the surgical navigationunit monitors the extent to which the implant is driven into the bone.If it appears that continued driving of the implant into the bone isinappropriate, the surgical navigation unit 350 causes a warning to bepresented. The surgical navigation unit 350 also inhibits the controlconsole 28 for supplying energization signals to the handpiece 22 buntil the warning is acknowledged.

Also, as mentioned above with respect to the data stored in chipcontroller/memory 84, this component may contain data that indicates theextent to which the cutting accessory is worn. One means of determiningcutting accessory wear is now described by reference to FIG. 23.Specifically, controller 70, in addition to monitoring the amount oftime a cutting accessory is actuated monitors the voltage applied to thehandpiece that actuates the cutting accessory as well as the currentdrawn by the handpiece, step 370. When the handpiece motor is actuated,controller 70 performs step 372, a power consumed calculation for thehandpiece. In step 372, based on the voltage applied to the handpiece,the current drawn and the time the handpiece was used, controller 70determines the Watts minutes of power consumed by the handpiece.

Then, once the handpiece motor is turned off, in step 374, datarepresentative of the power consumed by the handpiece is then written bythe controller 70 into the WEAR PROFILE data field 112 of controllermemory 84.

It should be understood that the data in the WEAR PROFILE data field 112are used in the same generally manner as the data in the TIME USED field110 are used. Specifically, these data are read by controller 70. Duringthe use of the cutting accessory, in a location within the memoryintegral with control console 28 data representative of the cumulativewatt minutes of power consumed in actuating the cutting accessory arestored. These data are based on the data read from the WEAR PROFILEfield 112 as well as the data generated as a result of the periodicexecution of steps 370 and 372 when the handpiece motor is actuated.These data representative of total cutting accessory wear are comparedto a reference value. This reference value may be from data read fromchip 62, (data storage field not shown) from the handpiece or a setvalue in the control console memory 69. If this comparison indicatesthat the total amount of power employed to drive the cutting accessoryexceeds the reference value, a warning message is generated on theconsole display 71. This provides the surgeon with an indication thatthe cutting accessory may be worn to a level that the efficiency of theaccessory has appreciably diminished.

FIG. 24 depicts in block diagram components internal to a controlconsole to which plural handpieces may be simultaneously attached.Specifically, there is a first processor, main controller 380, and asecond processor, accessory interrogator 382. The main controller 380 isthe processor that has primary responsibility for generating the commandsignals to the drivers internal to the control console that supply theenergization signals to the individual handpieces 22 a, 22 b and 22 c,(drivers not shown). The input signals into main controller 380 includethe characteristics of the individual handpieces as well as thesurgeon-originating command signals that indicate the rate at which thehandpieces are to be actuated.

The input signals into main controller 380 also include the data readfrom the identification chips 62 integral with the cutting accessories24 attached to the individual handpiece 22 a, 22 b, and 22 c. These dataare retrieved by the accessory integrator 382. Once the accessoryinterrogator 382 retrieves these data, the interrogator forwards thesedata to the main controller 380. The main controller 380, in turn,generates command signals to the drivers to cause each handpiece 22 a,22 b and 22 c to be actuated appropriately for the attached cuttingaccessory 24.

FIG. 25 depicts one protocol for retrieving data from the cuttingaccessory identification chips. Specifically, after the main controller380 determines that a handpiece 22 a, 22 b or 22 c is connected to oneof the control console 28 connections, the main controller instructs theaccessory interrogator 382, to initiate an interrogation sequence forthat handpiece, (step not shown). Initially, the interrogation sequenceconsists of accessory interrogator 382 generating a request that anyattached accessory write back one specific type of data. This request,represented by step 388, is performed so that the accessory interrogator382 can determine whether or not an accessory is even attached to thehandpiece 22 a, 22 b or 22 c. The accessory interrogator 382 performsthis write request and waits for data step continually, as long as thereis an attached handpiece. In one version of the invention, the specificdata the accessory interrogator 382 requests is the cutting accessoryserial number.

Upon attachment of a cutting accessory 24 to a handpiece 22 a, 22 b or22 c, the identification chip in the accessory will, in response to thewrite request, read out the serial number. Upon receipt of these data,accessory interrogator requests that all the data in the accessoryidentification chip 64 be written back. This write request and thesubsequent data write out, are represented by step 390. In step 392 theidentification chip data used to control operation of the cuttingaccessory 24 are forwarded to the main controller 380. The maincontroller, as discussed previously with regard to step 126, configuresthe system so that energization signals will be supplied to thehandpiece 22 a, 22 b or 22 c that will cause the appropriateenergization of the attached cutting accessory 24.

After the data are read from the accessory identification chip 62, theaccessory interrogator 382 continually generates a read request for theserial number of the accessory. This serial number is continuouslycompared to the serial number originally read for the cutting accessory.The read-request, data write and comparison steps collectivelyrepresented as step 394. These steps are performed in order to ensurethat the same cutting accessory 24 remains attached to the handpiece 22a, 22 b or 22 c. As long as the same cutting accessory is attached tothe particular handpiece, there is no change in the overall operation ofthe system.

If, however, the serial number is different, or no serial number isreturned, the accessory interrogator 382 interprets the responseindicating the accessory was removed or switched. Accessory interrogator382 then proceeds to step 396. In step 396, the accessory interrogatorgenerates a message to the main controller 380 informing the maincontroller of the disconnect of the cutting accessory. The maincontroller 380, in a step not shown, then regulates the energization ofthe associated handpiece as is appropriate for a cutting accessory notbeing attached. This particular regulation may, for example, consist ofthe inhibiting of the actuation of the handpiece.

The accessory interrogator 382 then reexecutes step 388. Step 388 isagain repetitively reexecuted until it receives a serial numberindicating a cutting accessory 24 has again been attached to thehandpiece.

An advantage of the above arrangement is that, the majority of readrequests generated by the accessory interrogator and subsequent datawrites by the accessory NOVRAMs 32 are for relatively small amounts ofdata. This makes it possible for the accessory interrogator to, in arelatively short amount of time, monitor whether or not accessories 24are attached to each of the handpieces 22 a, 22 b and 22 c. Thus, in theevent there is a removal or replacement of the cutting accessoryattached to any one of the handpiece 22 a, 22 b or 22 c, the accessoryinterrogator will detect this change, typically within 50 msec. or lessof the event. Main controller 380 is then promptly informed of thisstate change so as to substantially eliminate the likelihood that ahandpiece will be actuated even though there is no attached accessory,or actuated in an inappropriate manner for the attached handpiece.

An alternative protocol for reading data from a cutting accessoryidentification chip 62 is now described by reference to FIG. 26. Here anaccessory present read-request and receive written data step 402,identical to step 388, is performed as before whenever a handpiece 22 a,22 b or 22 c is connected to a control console 28. However, if theaccessory interrogator 382 does not provide the main controller 380 witha data from accessory identification chip 62, in step 404, the maincontroller sets the control console to energize the handpiece 22 a, 22 bor 22 c based on default setting for the handpiece. These settings arebased on data in the handpiece NOVRAM. Accessory interrogator 382 andmain controller 380 repetitively reexecute steps 402 and 404,respectively, until data are returned by an accessory identificationchip 62.

Once data, again typically a serial number, are returned by theidentification chip 62 of a newly installed cutting accessory 24, theaccessory interrogator requests all the data in the chip, represented bystep 406. These data are forwarded by the accessory interrogator 382 tothe main controller 380, step not illustrated. Based on these data, instep 408, the main controller resets the data used to control thehandpiece so that the handpiece 22 a, 22 b or 22 c is energizedappropriately for the attached cutting accessory 24. As before, evenwhen the handpiece 22 a, 22 b or 22 c is energized, the accessoryinterrogator 382 continues to request the serial number information fromthe accessory identification chip 62 to determine whether or not it haschanged, step 410.

If, in step 410, it is determined that there has been a change in thecutting accessory 24 attached to the handpiece step 402 is againexecuted. Depending on the results of the inquiry performed in step 402either step 404 or step 406 is again executed.

An advantage of this method of operation is that there may be somehandpieces that are used primarily with one particular type of cuttingaccessory. The cutting accessory with which the handpiece is most oftenused is not provided with an identification chip. The handpiece NOVRAM32 contains data setting the handpiece to operate in accordance with thecharacteristics of this particular cutting accessory. Thus, in thisversion of the invention, the cost of providing the most often usedcutting accessory with an identification chip is eliminated.

A more detailed explanation of how the cutting accessory and implantrecognition system of this invention can be used in combination with asurgical navigation unit 350 is now described by reference to FIG. 27.Specifically, this invention can be used to facilitate the placement ofan implant in a patient. As represented by step 420, initially thesurgical navigation unit 350 is employed to measure the portion of thebody of the patient to which the implant is to be fitted. Then, asrepresented by step 422, as part of the procedure, the surgicalnavigation unit generates a message prompting the surgeon to select animplant, or a particular component of an implant, for fitting to thepatient.

The surgeon then identifies the implant 330, as represented by step 424.In this step, the surgeon identifies the specific implant by placing thehandpiece 22 or cutting accessory 24 in close proximity to the implantso that the data in the implant chip 336 can be inductively written tothe control console 28. In some versions of the invention, a passivesurgical instrument, like a pointer with a built in coil, may be used toperform this data read-request and receive the written out data.

The data identifying the implant are written to the surgical navigationunit 350. The surgical navigation unit 350, in turn, based on inputvariables such as the dimensions of the implant and the measurements ofthe patient's body, determines whether or not the implant is appropriatefor the procedure being performed, verify implant step 426. If, in step426, the surgical navigation unit 350 determines that the implant mightbe inappropriate for the procedure, for example, the size appearsinappropriate for the position in the body in which it is to be placed,the surgical navigation unit generates a warning to the surgeon, stepnot shown.

The next step in the procedure is the prompting by the surgicalnavigation unit 350 of the accessory that is to be used to fit theimplant, step 428. The surgical navigation unit, in step 430, verifiesthat the accessory is the appropriate accessory for driving the implant.If an inappropriate accessory is selected, an appropriate warning ispresented, warning step not shown.

In step 432 the surgical navigation unit 350 determines whether or notthe accessory and implant are ready for the fitting of the implant. Thisstep is performed by determine whether or not the signal transferred tothe accessory coil 342 indicates the implant 330 is fitted to theaccessory. Once the accessory and implant are ready for implantinstallation, the surgical navigation unit, in step 434, presents onmonitor 352 information about the exact surgical sub procedure that isperformed to fit the implant. This information may include an image ofthe site where the implant is to be fitted. This information may alsoinclude textual commentary regarding aspects of the procedure.

Thus, the integrated system of this invention provides guidance andprompts to the surgeon to facilitate the execution of the surgicalprocedure. This can minimize the time the patient is held underanesthesia which is one of the goals of modern surgery. Also, theimplant and accessory verification steps serve to reduce the likelihoodthat an inadvertent oversight causes a surgeon to attempt to use a lessthan optimal component during a surgical procedure.

The cutting accessory and implant recognition system of this inventionis also used to assist in the inventory of components used during asurgical procedure. As seen by reference to FIG. 28, components 440 a,440 b, . . . 440 f used to perform the procedure are kept in a case 442.For example, certain instruments may be held in a sterilization case.Alternatively trial implant components are held in a trial case.

As part of the procedure, the control console 28, in step 444,determines when a component is used. This determination occurs when anaccessory is fitted to a handpiece or another device, for example animplant or an implant trial unit, is fitted in place with the handpieceor cutting accessory. As discussed above, the data in the chip integralwith this instrument or implant is inductively read.

As a consequence of this component used determination, a local inventoryof used components is updated, step 446. A database in which theseinformation is stored, a local inventory database 480, is connected tothe control console as discussed below with respect to FIG. 30. Data arewritten to and read from this database 480 by a dedicated processor, notshown.

Eventually, there is a point in the procedure in which it is time toinventory the used components to ensure that their whereabouts are knownand they are properly stored. Typically this point is near the end ofthe procedure. At this time, the processor associated with the localinventory database 480 identifies a component that needs for whichaccounting is required, step 448. The identity of this component is sentto either the control console 28 or the surgical navigation unit 350.The device that receives this information, in step 450, requests thesurgical personnel to locate this component. In response to thisrequest, also part of step 450 in FIG. 29, the personnel return thecomponent 440 a, 440 b. . . or 440 f to the case 442 in which thecomponent is stored and inductively read the stored identifyinginformation for the component.

Data indicating that the component has been properly returned to thecase 442 are forwarded to the processor associated with the localinventory database 480. This processor, in step 452, updates theinventory for the particular case 442. The local inventory databaseprocessor then reexecutes step 448. If there are still missingcomponents, step 450 is reexecuted and one of the remaining missingcomponents is again identified. However, in step 448 it may bedetermined that all the components are accounted for. If the localinventory database processor makes this determination, this processorcauses the control console 28 or navigation unit 350 to display amessage indicating that the inventory is complete, step 454.

The above aspect of this invention facilitates the checking of equipmentused during surgery to ensure the whereabouts of this equipment isknown.

As mentioned above, and now described by reference to FIG. 30, theinformation generated by the accessory and implant recognition system ofthis invention may be employed by components other than the controlconsole that drive the handpieces used to actuate the accessories.Specifically, as seen in this Figure, the control console that reads theaccessory and implant identify data may be attached to a local areanetwork to which other equipment both in the operating room andelsewhere in the medical facility are attached. In one version of anetwork it is contemplated that this data transfer be over a serial busin accordance with the IEEE-1394 data transfer protocol.

Three devices attached this network are the control console 28, thesurgical navigation unit 350 and the local inventory database 480.

The facility's billing processor, represented by node 482 is alsoattached to this network. The billing processor receives data packetsidentifying the patient-chargeable components identified by the controlconsole that are used during the procedure. This facilitates theaccurate charging of the patient for the equipment used during thesurgical procedure.

The records of components used are also forwarded to facility's primaryinventory control database, node 484. This allows the processor thatmonitors inventory levels of the accessories and implants to determinewhen the additional equipment needs to be shipped, represented bysupplier ship node 486. Also, some suppliers only bill the facility whenthe equipment is actually used. The inventory control database, uponreceiving an indication that some equipment has been used, through asupplier bill node 488 informs the supplier's processor of this event.This arrangement thus makes it possible to ensure that a facility isonly billed for equipment when the equipment is used.

Also the database in the facility that maintains patient records,represented by node 490, receives an indication of the cuttingaccessories, trial components, and implants fitted during the surgicalprocedure. Thus, medical personnel do not, during the procedure have tospend time documenting what specific components where used during theprocedure. Since the use of these components can readily be datastamped, the personnel likewise do not have to document when thesecomponents were used.

Also, there is no reason that in all versions of the invention the tagsbe inductively coupled to the complementary handpieces in which theiraccessories are inserted. In some versions of the invention, there maybe physical connections between the exposed contacts that are part ofthe handpiece and accessory. These contacts, upon physical abutment,establish the connection between the accessory tag and the conductors inthe handpiece that extend to the control console.

Furthermore, in some versions of the invention, the coil thatinductively couples the signal to the cutting accessory may not be inthe handpiece. In some versions of the invention, this coil may belocated in the control console. Whenever a new cutting accessory isattached to the handpiece, information about this event is sensed by adevice internal to the handpiece and a signal representative of thisevent is forwarded to the control console. The control console thengenerates a message directing the surgeon to place the handpiece andcutting accessory sub-assembly adjacent a particular location on thecontrol console to facilitate the inductive transfer of signals betweenthe console and the accessory tag. An advantage of this version of theinvention is that it eliminates the need to provide additionalconductors in the cable that extends to the handpiece.

Another embodiment of the invention is shown in FIG. 31. In thisembodiment, no cable connects the handpiece or cordless powered surgicaltool to a control console. The Applicant's Assignee's U.S. patentapplication, CORDLESS, POWERED SURGICAL TOOL Ser. No. 10/210,325, filedon Aug. 1, 2002, now U.S. Pat. No. 6,960,894 B2, and incorporated hereinby reference, provides details of a physical structure of a cordlesspowered surgical tool. Likewise Applicant's Assignee's U.S. Pat. No.5,747,953 entitled CORDLESS, BATTERY OPERATED SURGICAL TOOL, issued May5, 1998, and incorporated herein by reference, describes a surgical toolthat may be modified to include the circuit arrangement shown in FIG.31.

As shown in FIG. 31, the cutting or operating end of the cordlesssurgical tool 522 is provided with an annular coil 566. Collectively,the cordless surgical tool 522 and cutting accessory 524 are shaped sothat coils 564 and 566 are in such proximity to each other that theywill collectively inductively transfer signals from/to the circuitinternal to the surgical tool 522 to/from the circuit internal to theidentification chip 562. Typically, the housing of the surgical tool 522is formed of materials discussed in Applicant's above patent documents.

The surgical tool 522 includes a battery 590 that supplies power, asnecessary, to the circuit elements therein (connections not shown). Acontroller 570 controls the overall operation of the system. Memory 569in the surgical tool 522 contains the permanent operating instructionsthat are executed by controller 570 to control the system and regulatethe actuation of the surgical tool 522 and the cutting accessory 524.Controller 570 generates energization control signals to a driver 572.The energization control signals are based on the cutting accessory 524identified and the value selected by a manual actuator device 549. Themanual actuator device 549 can be a trigger type push button controllingthe output from a variable resistor or any other type of deviceproviding a variable signal output. The driver 572, based on the valueof the output from the manual actuator device 549 and the cuttingaccessory 524 identified, generates the energization signals that areapplied to the surgical tool motor 526.

The surgical tool 522 can also include a touch screen display 571 orother type of indicator/input system. Controller 570 causes informationregarding the state of the system to be presented on the display 571.Controller 570 can also cause images of buttons to be presented on thedisplay 571. An operator regulates the operation of the system byselectively depressing these buttons. In other embodiments, no indicatoror display is present. The system automatically controls the cuttingaccessory 524 based on the accessory identified. For example, themaximum operating speed of the cutting accessory 524 can be varieddepending of the accessory identified.

The surgical tool 522 also includes a modulator (MOD) 574 that modulatesdigital signals output by controller 570 so they can be inductivelytransferred to cutting accessory identification chip 562. In onepreferred version of the invention, modulator 574 receives afixed-frequency signal from an oscillator 576 internal to the surgicaltool 522.

Modulator 574 produces an amplitude shift keyed signal generated bymodulator 574 that is amplified by an amplifier 578. The output signalfrom amplifier 578 is applied to one end of coil 566.

Demodulator 580 receives a signal that is coupled to coil 566,demodulates the signal, and applies the output bit stream to controller570.

The identification chip 562 can include a small controller and anelectronically programmable memory (μC & MEM) 584. The controllerintegral with controller/memory 584 controls the writing of data intoits complementary memory section and the reading out of the contents ofthe memory. Modulator/demodulator (MOD DEM) 586, clock 588, capacitor583 and power regulator 589 function in substantially the same manner asdescribed for the embodiment in FIG. 3.

In FIG. 31, coil 564 is shown as being integrally part of chip 562. Thisis one option for the invention. However, as discussed above, it isanticipated that in many versions of the invention, chip 62 and coil 564will be separate components.

Some of the different types of data stored in the tag controller/memory584 include a serial number specific to the cutting accessory 524 withwhich tag 562 is integral. This number may also include a specialauthorization code. There is also stored data that indicates the type ofcutting accessory 524. For example, the cutting accessory 524 may be adrill, saw, burr, linkage assembly for converting rotary movement to aback-and-forth movement, or other types of elements. In cases where alinkage assembly is utilized, an identification tag may be provided onthe linkage assembly as well as a cutting element secured to the linkageassembly. The linkage assembly can function as an intermediateattachment between the surgical tool 522 and the cutting accessory 524in a manner similar to the arrangement shown in FIG. 20.

The stored data can include the size, diameter, physical materials, andtype of cutting accessory 524. The data can also include the preferredoperating speed, maximum operating speed, maximum operating torque,stopping torque, or other type of information regarding operation of thecutting accessory 524. The mode of operation of the cutting accessory524, such as oscillatory or unidirectional can also be provided with thedata.

Data indicating if and when the cutting accessory 524 was previouslyused, and for how long can be read and written to the chip 562. Dataindicating how long a surgeon can expect to use the cutting accessory524 before the cutting/drilling surfaces become worn to the level atwhich they may not efficiently cut tissue can be read/stored.

The cordless surgical tool 522 of FIG. 31 operates in a similar mannerto the handpieces connected by cables 30 in embodiments discussed above.

In another embodiment, the accessory 524 comprises an implant device,such as a screw or other element that is directly implanted into thebody of a patient using the surgical tool 522. In this instance, thecharacteristics of the accessory element are provided to the surgicaltool 522 regarding desired torque, operating speed, etc. for implantingthe implant device.

Therefore, it is an object of the appended claims to cover all suchvariations and modifications that come within the true spirit and scopeof this invention.

What is claimed is:
 1. A powered surgical handpiece, said handpiecehaving: a housing, said housing having a first bore with an open end forremovably receiving a cutting accessory and that extends inwardly intosaid housing; a motor disposed in said housing, said motor including acoupling assembly disposed in the housing first bore for engaging thecutting accessory so that, upon actuation of said motor, the cuttingaccessory is driven by said motor; a locking assembly mounted to saidhousing, said locking assembly having a member that engages said cuttingaccessory so as to removably hold said cutting accessory in the housingfirst bore; and a flexible carrier, said flexible carrier having firstand second sections, each section having a longitudinal axis wherein:the longitudinal axis of the second section is angularly offset from thelongitudinal axis of the first section; conductive traces are formed onthe sections and are connected to each other; the carrier first sectionis wound in a closed circular pattern and disposed in a portion of saidhousing the defines the housing first bore so that the conductive traceon the carrier first section forms a coil that extends circumferentiallyaround said housing first bore that is capable of inductively exchangingsignals with the cutting accessory; and the carrier second sectionextends proximally from the carrier first section through said housingso that the conductive trace on the carrier second section functions asa conductor internal to said housing that extends to said coil.
 2. Thesurgical handpiece of claim 1, wherein said locking assembly member ismoveably attached to said housing.
 3. The surgical handpiece of claim 1,wherein said housing is further formed to define a second bore thatextends from the first bore to a location spaced from the first boreopening through which a suction is drawn.
 4. The surgical handpiece ofclaim 1, wherein: said housing is formed with a second bore separatefrom said first bore that is connected to the first bore; and the secondsection of said flexible carrier is disposed in the housing second bore.5. The surgical handpiece of claim 1, wherein an impedance matchingcircuit is attached to the second section of said flexible carrier andis connected to said coil formed by the conductive trace on the firstsection of said flexible carrier.
 6. The surgical handpiece of claim 1,wherein: internal to said housing is an annularly shaped structuralmember having an inner surface that at least partially defines thehousing first bore, said annularly shaped structural member beingfurther shaped to define a groove that extends around and is separatedfrom the housing first bore; and the first section of said flexiblecarrier is disposed in the groove defined by the annularly shapedstructural member.
 7. A powered surgical handpiece, said handpiececomprising: a body having a distal end, said body having a first borethat is open at the body distal end, the first bore dimensioned forremovably receiving a cutting accessory; an annularly shaped structuralmember disposed in said body adjacent the distal end, said structuralmember shaped to have an inner wall that at least partially defines thebody first bore and that defines a groove that extends annularly aroundthe body first bore and that is isolated from the body first bore; amotor disposed in said housing, said motor including a coupling assemblydisposed in the body first bore for engaging the cutting accessory sothat, upon actuation of said motor, the cutting accessory is driven bysaid motor; a locking assembly mounted to said body, said lockingassembly having a member that engages said cutting accessory so as toremovably hold said cutting accessory in the body first bore; a flexiblecarrier, said flexible carrier having formed thereon at least oneconductive trace wherein: said carrier has a first section with alongitudinal axis and a second section that is contiguous with the firstsection and that has a longitudinal axis that extends angularly awayfrom the longitudinal axis of the first section; the first section ofsaid flexible carrier, including said conductive trace on the firstsection, is wound in a closed circular pattern and disposed in thegroove defined by said annularly shaped structural member so that theconductive trace on the carrier first section forms a coil that extendscircumferentially around said housing first bore that is capable ofinductively exchanging signals with the cutting accessory; and thecarrier second section extends proximally away from the groove so thatthe conductive trace on the carrier second section functions as aconductor that extends to said coil.
 8. The surgical handpiece of claim7, wherein said body is further formed to define a second bore thatextends from the first bore at a location spaced from the first boreopening through which a suction is drawn.
 9. The surgical handpiece ofclaim 7, wherein: said body is formed with a second bore separate fromsaid first bore that is connected to the first bore; and the secondsection of said flexible carrier is disposed in the second bore of saidbody.
 10. The surgical handpiece of claim 7, wherein an impedancematching circuit is attached to the second section of said flexiblecarrier and connected to the coil-forming conductive trace on the firstsection of said carrier.
 11. The surgical handpiece of claim 7, whereinsaid annularly shaped structural is member is shaped so that the groovedefined by said structural member extends inwardly from andcircumferentially around an outer surface of said structural member. 12.The surgical handpiece of claim 7, wherein the flexible carrier firstsection overlaps the flexible carrier second section and a conductiveconnection extends from the conductive trace on the flexible carrierfirst section to the conductive trace on the flexible carrier secondsection.
 13. The surgical handpiece of claim 7, wherein the first andsecond sections of said flexible carrier are collectively L-shaped. 14.A powered surgical handpiece, said handpiece having: a body, said bodyhaving a first bore with an open end for removably receiving a cuttingaccessory and that extends inwardly into said body: a motor disposed insaid housing, said motor including a coupling assembly disposed in thebody first bore for engaging the cutting accessory so that, uponactuation of said motor, the cutting accessory is driven by said motor;a locking assembly mounted to said body, said locking assembly having amember that engages said cutting accessory so as to removably hold saidcutting accessory in the body first bore; a flexible circuit, saidflexible circuit having formed thereon at least one conductive tracewherein: said flexible circuit is formed to have first and secondsections such that the flexible circuit first and second sections havelongitudinal axes that are angularly offset from each other; the firstsection of said flexible circuit, including the conductive trace on thefirst section, is wound in a closed circular pattern and disposed in aportion of said housing the defines the body first bore so that theconductive trace wound in a circular pattern forms a coil that extendscircumferentially around said housing first bore capable of inductivelyexchanging signals with the cutting accessory; and the second sectionextends proximally away from the first section so that the conductivetrace of the flexible circuit second section functions as a conductorthat extends to said coil; and an impedance matching circuit mounted tothe second section of said flexible circuit, said impedance matchingcircuit being connected to said at least one conductive trace tofunction as an impedance matching circuit for said coil.
 15. Thesurgical handpiece of claim 14, wherein said body is further formed todefine a second bore that extends from the first bore at a locationspaced from the first bore opening through which a suction is drawn. 16.The surgical handpiece of claim 14, wherein: said body is formed with asecond bore separate from said first bore that is connected to the firstbore; and the second section of said flexible circuit is disposed insaid the housing body second bore.
 17. The surgical handpiece of claim14, wherein: an annular member is disposed in said body, said annularmember having an inner wall that at least partially defines the bodyfirst bore and defining a groove that extends circumferentially aroundthe body first bore that is isolated from the body first bore; and thefirst section of said flexible circuit is disposed in the groove definedby said annular member.
 18. The surgical handpiece of claim 17, whereinsaid annular member is separate component from said body.
 19. Thesurgical handpiece of claim 14, wherein: the flexible circuit firstsection is wound over a portion of the flexible circuit second section;and where the flexible circuit first section overlaps the flexiblecircuit second section, a conductive connection extends from saidconductive trace on the flexible circuit first section to the conductivetrace on the flexible circuit second section.
 20. The surgical handpieceof claim 14, wherein the first and second sections of said flexiblecircuit are collectively L-shaped.